3/31/25, 12:22 AM SIS 2.

2012/09/18 Air Inlet and Exhaust System (SENR9832-72)

SMCS - 1050 i04984833

PSP
202 -000C
5
18: /03/3 B74D
5
SEN 2:11+ 0
© 2 R983 05:30
025 2
Cat
erp
illa
Illustration 1
r In g01115385
(1) Inlet to the engine
(2) Aftercooler core
(3) Inlet air line
(4) Exhaust outlet from turbocharger
c.
(5) Turbine side of turbocharger
(6) Compressor side of turbocharger
(7) Air cleaner
The engine components of the air inlet and exhaust system control the quality of air and the
amount of air that is available for combustion. The components of the air inlet and exhaust
system are the following components:

Air cleaner

Turbocharger

Aftercooler

Cylinder head

Valves and valve system components

Piston and cylinder

Exhaust manifold

The turbocharger compressor wheel pulls inlet air through the air cleaner and into the air inlet.
The air is compressed and this compression causes the air to become hot. The air flows through
aftercooler core (2) and the temperature of the compressed air lowers. This lowering of the

https://sis2.cat.com/?_ts=1743353544288#/print-preview/service/cb8ee41d-f309-4179-abb1-54880b2290e4 1/7
3/31/25, 12:22 AM SIS 2.0

temperature helps to provide increased horsepower output. Aftercooler core (2) is a separate
cooler core that is mounted along the side of the engine radiator. The engine fan causes ambient
air to move across both cores. This air movement cools the turbocharged inlet air and the engine
coolant.

Air is forced from the aftercooler into inlet manifold (1). The air flow from the inlet port into the
cylinders is controlled by inlet valves.

Illustration 2 g01319128
Air inlet and exhaust system
(2) Aftercooler core
(4) Exhaust outlet
(5) Turbine side of turbocharger
(6) Compressor side of turbocharger
(8) Exhaust manifold
(9) Exhaust valve
(10) Inlet valve
(11) Air inlet

Each cylinder has two inlet valves (10) and two exhaust valves (9) in the cylinder head. The inlet
valves open on the inlet stroke. When the inlet valves open, compressed air from the inlet port
within the inlet manifold is pushed into the cylinder. The inlet valves close when the piston begins
the compression stroke. The air in the cylinder is compressed and the fuel is injected into the
cylinder when the piston is near the top of the compression stroke. Combustion begins when the
fuel mixes with the air. The force of combustion pushes the piston on the power stroke. The
exhaust valves open and the exhaust gases are pushed through the exhaust port into exhaust

https://sis2.cat.com/?_ts=1743353544288#/print-preview/service/cb8ee41d-f309-4179-abb1-54880b2290e4 2/7
3/31/25, 12:22 AM SIS 2.0

manifold (8). After the piston finishes the exhaust stroke, the exhaust valves close and the cycle
begins again.

Exhaust gases from the exhaust manifold flow into the turbine side of turbocharger (5). The high
temperature exhaust gases cause the turbocharger turbine wheel to turn. The turbine wheel is
connected to the shaft that drives the compressor wheel. Exhaust gases from the turbocharger
pass through exhaust outlet (4), through a muffler, and through an exhaust stack.

Turbocharger

Illustration 3 g01319169
Turbocharger
(12) Air inlet
(13) Compressor housing
(14) Compressor wheel
(15) Bearing
(16) Oil inlet port
(17) Bearing
(18) Turbine housing
(19) Turbine wheel
(20) Exhaust outlet
(21) Oil outlet port
(22) Exhaust inlet
The turbocharger is mounted to the exhaust manifold of the engine. All of the exhaust gases go
from the exhaust manifold through the turbocharger.

https://sis2.cat.com/?_ts=1743353544288#/print-preview/service/cb8ee41d-f309-4179-abb1-54880b2290e4 3/7
3/31/25, 12:22 AM SIS 2.0

The exhaust gases enter the turbocharger and the turbine wheel is turned. Because the
turbocharger turbine wheel is connected by a shaft to the turbocharger compressor wheel, the
turbine wheel and the compressor wheel turn at very high speeds. The rotation of the
compressor wheel pulls clean air through the compressor housing air inlet. The action of the
compressor wheel blades causes a compression of the inlet air. This compression allows a
larger amount of air to enter the engine. With more air in the engine, the engine is able to burn
more fuel. The overall effect is an increase in power.

Illustration 4 g01319184
Turbocharger with wastegate
(23) Canister
(24) Actuating lever

The engine can operate under conditions of low boost (lug). Low boost is a condition that occurs
when the turbocharger produces less than optimum boost pressure. There is a spring that is
inside canister (23). Under low boost, the spring pushes on the diaphragm in canister (23). This
moves actuating lever (24). The actuating lever closes the wastegate, which will allow the
turbocharger to operate at maximum performance.

Under conditions of high boost, the wastegate opens. The open wastegate allows exhaust gases
to bypass the turbine side of the turbocharger. When the boost pressure increases against the
diaphragm in canister (23), the wastegate is opened. The rpm of the turbocharger is limited by
bypassing a portion of the exhaust gases around the turbine wheel of the turbocharger.

Note: The calibration of the wastegate is preset at the factory. No adjustment can be made to
the wastegate.

Bearing (15) and bearing (17) in the turbocharger use engine oil that is under pressure for
lubrication. The lubrication for the bearings flows through oil inlet port (8) and into the inlet port in
the center section of the turbocharger cartridge. The oil exits the turbocharger through oil outlet

https://sis2.cat.com/?_ts=1743353544288#/print-preview/service/cb8ee41d-f309-4179-abb1-54880b2290e4 4/7
3/31/25, 12:22 AM SIS 2.0

port (21). The oil then returns to the engine oil pan through the oil drain line for the turbocharger.
The oil then returns to the engine oil pan through the oil drain line for the turbocharger.

The turbocharger center housing of the turbocharger is cooled by engine coolant. The coolant
flows from the thermostat housing to the turbocharger center housing. The coolant flow keeps
the components of the turbochargers center housing cool in order to prevent oil coking in the
bearing area.

Valves And Valve Mechanism

Illustration 5 g01319198
Valve system components
(25) Valve bridge
(26) Rocker arm
(27) Camshaft
(28) Rotocoil
(29) Valve spring
(30) Valve guide
(31) Valve
The valves and the valve mechanism control the flow of inlet air into the cylinders during engine
operation. The valves and the valve mechanism control the flow of exhaust gases out of the
cylinders during engine operation.

https://sis2.cat.com/?_ts=1743353544288#/print-preview/service/cb8ee41d-f309-4179-abb1-54880b2290e4 5/7
3/31/25, 12:22 AM SIS 2.0

Illustration 6 g01319199
Components of the gear train
(32) Timing mark
(33) Camshaft gear
(34) Adjustable idler gear
(35) Idler gear
(36) Timing mark
(37) Cluster gear
(38) Crankshaft gear
(39) Oil pump gear

The inlet valves and the exhaust valves are opened by the valve mechanism. The inlet valves
and the exhaust valves are also closed by the valve mechanism. This occurs as the rotation of
the crankshaft causes camshaft (27) to rotate. Camshaft gear (33) is driven by a series of two
idler gears (34) and (35). Idler gear (34) is driven by cluster gear (37). Cluster gear (37) is driven
by crankshaft gear (38). Timing mark (32) and timing mark (36) are aligned in order to provide
the correct relationship between the piston and the valve movement.

The camshaft has three lobes for each cylinder. One lobe operates the inlet valves. A second
lobe operates the exhaust valves. The third lobe operates the unit injector mechanism. The
camshaft lobes turn and the rocker arms move. Movement of the rocker arms will make the inlet
https://sis2.cat.com/?_ts=1743353544288#/print-preview/service/cb8ee41d-f309-4179-abb1-54880b2290e4 6/7
3/31/25, 12:22 AM SIS 2.0

and exhaust valve bridges move. These bridges allow one rocker arm to actuate two valves at
the same time. Each cylinder has two inlet valves and two exhaust valves. Each valve has one
valve spring (29). The spring closes the valve.

Rotocoils (28) cause the valves to rotate while the engine is running. Valve rotation provides a
longer service life. Valve rotation also minimizes carbon deposits on the valves.

Adjustable idler gear (34) is designed to provide the required gear backlash between
nonadjustable idler gear (35) and camshaft gear (33). If the cylinder head is removed, tolerances
of the components will change. The components that change are the cylinder head and the head
gasket. The adjustable idler gear must be relocated. For information on setting the correct
backlash, refer to Testing and Adjusting, "Gear Group (Front) - Time".

The camshaft drive gear has integral pendulums which act as a vibration damper for the front
gear group. These pendulums are designed to counteract the torsional forces from the injector
pulses. This eliminates vibration and noise. The engine also runs smoother at all operating
speeds.

PSP-000CB74D
2025/03/30
18:52:07+05:30
i02209391
© 2025 Caterpillar Inc.

https://sis2.cat.com/?_ts=1743353544288#/print-preview/service/cb8ee41d-f309-4179-abb1-54880b2290e4 7/7